Issue 40
Kilfrost heralds a new dawn for plant temperature control
Issue 40
CONTENTS AMP Magazine is an engaging, editorially led publication & directory giving the reader news and updates on innovative products and services to our ever progressing industry.
Publishing House Jet Digital Media Ltd, The Forge, Spratling Court Offices, Spratling Court Farm, Manston, Kent, CT12 5AN Publication Manager Brett Sutton 01843 580460 brett@amp-magazine.co.uk
Sales Executive Julian Phipps 01843 580460 julian@amp-magazine.co.uk
Editor Tina Curtis 01843 580460 tina@amp-magazine.co.uk
‘Kilfrost heralds a new dawn for plant temperature control’
Kilfrost is a third-generation owned and managed family company, recognised as the global leader in safety critical chemistry and rheology. Kilfrost maintains a proud focus on pioneering the next generation of products to raise industry standards, and to meet the growing needs of its commercial clients and the wider community. Compared to existing fluids based on Propylene Glycol, Ethylene Glycol and Ethanol, Kilfrost ALV Plus offers significantly lower resistance to slushing at low temperatures, is non-toxic and formulated with organic, approved inhibitors and viscosity modifiers. It requires less pumping energy, and offers fewer pressure drops in existing systems bringing significant savings through lower electricity costs. For new systems, they can now be designed with smaller pumps, smaller heat exchangers, and lower diameter pipework meaning significant capital and cost of ownership savings.
It has continued to bring its expertise to new industries and has developed a new range of Advanced Low Viscosity, heat transfer fluids. The range includes ALV Plus, which for the first time ever provides a commercial solution for breweries to the longstanding efficiency-versus-toxicity challenge. As well as having NSF/FDA accreditation as food and beverage safe, the fluid also exhibits excellent low viscosity performance at temperatures as low as minus 40 Deg C and as high as 75 Deg C.
At the concentrations required for its effective use, Ethanol-based fluids present a fire risk which is obviously undesirable and an insurance hazard. ALV Plus also offers superior corrosion resistance and can be used across a very wide range of metals, plastics and rubber compounds. ALV Plus is already in use at craft breweries in the UK and the USA and is quickly building a reputation as the environmentally-friendly, low risk, cost-efficient heat transfer fluid for the Beverage, Food and other industries. Please see www.kilfrost.com for more details or call 01434 320332.
Kilfrost ALV Plus and Pillars Brewery With energy costs spiralling, the brewing industry has long been seeking a costeffective, efficient, and safe alternative to current heat transfer fluids. But for decades breweries have had one hand tied behind their backs as they are forced to choose a fluid that is either non-toxic or one that offers enhanced performance. Now scientists at Kilfrost, have answered that dilemma and launched a first-of-its-kind heat transfer fluid set to revolutionise food and drink processing and manufacture, and which for the first time provides a commercial solution to the long-standing efficiencyversus-toxicity challenge. AMP Magazine | 04 Issue 40
Pillars Brewery - credit: Pillars Brewery
Pillars Brewery Operators of Pillars Brewery, craft lager producers based in Walthamstow, London, were looking for the most efficient glycol product for use in cooling the Brewery’s fermentation tanks. But the brewery also needed a less viscous product than that which is generally used in brewing in order to crash cool their beer more quickly. Doing this means not only a reduction in electricity costs but means the brewery can stay true to its values.
Pillars turned to Kilfrost’s new ALV Plus fluid. Brewer and Pillars Founder, Gavin Litton, said: “Thanks to Kilfrost ALV Plus, our pumps are working less hard, using less energy to circulate liquids around the plant. We’ve been so impressed with the performance of the fluid, as it not only saves us money, but means we’re as energy-efficient and environmentally-friendly as possible. That’s at the heart of what we stand for as a brewery.”
When it comes to heat transfer, industry has faced the efficiency-vs-toxicity dilemma for too long. That’s set to change.
Kilfrost ALV Plus 4 Non-toxic, safer and more effective than market alternatives 4 Outperforms MEG, MPG, Bio-PDO and ethanol-based heat transfer fluids 4 Protects against corrosion and scaling 4 Free from nitrates, nitrites, borates, and heavy metals
Best of all? It’s organic and FDA/NSF accredited.
+44 (0)1434 320 332 // info@kilfrost.com // kilfrost.com //
@Kilfrost_Ltd
New Version Fluke 438-Ii Power Quality And Motor Analyser Can Also Be Used For Inverter Driven Motors Analyses electrical and mechanical performance on operational motors to extend system lifespan, without mechanical sensors
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he new version FlukeŽ 438-II Power Quality and Motor Analyser also supports measurements for inverter driven motors. The Fluke 438-II simplifies the process of motor performance diagnosis by providing analysis data for both the electrical and mechanical characteristics of the motor while it is in operation. It uses innovative algorithms to analyse not only three-phase power quality but also mechanical power, torque, efficiency and speed, to determine system performance and detect overloaded conditions, eliminating the need for potentially costly or inaccessible motor load sensors. To find out more, and how to obtain a free firmware upgrade for an existing 438-II, visit www.fluke.co.uk/438 Using proprietary algorithms, the Fluke 438-II measures the three-phase current and voltage waveforms and compares them against rated specifications to calculate motor mechanical performance. The analysis is presented in simple readouts, making it easy to gauge the operating performance and determine if adjustments are needed before failures cause an operational shut down. The Fluke 438-II analyser also provides measurements to determine a motor’s efficiency (i.e. the conversion of electrical energy to mechanical torque) and mechanical power under operating load conditions. These measures allow maintenance engineers to determine the motor’s in-service operating power compared to its rated power to determine if the motor is operating in overloaded condition or, conversely, if it is oversized for the application when energy may be wasted and operating cost increased. The 438-II is part of the Fluke 430 Series II of three-phase power quality and energy analysers that provide frontline troubleshooting and long-term trending to keep equipment running smoothly. For more information about all Fluke products, please visit the Fluke web site at www.fluke.co.uk.
AMP Magazine | 06 Issue 40
RAC Contractor of the Year 2017 - WINNERS!
On Wednesday 27th September 2017, JD Cooling Systems became RAC Contractor of the Year at this year’s RAC Cooling Industry Awards.
Going up against some of the top contractors from the industry, JD Cooling were announced as winners in front of over 500 professionals. Held at the London Hilton Park Lane Hotel, and now in its 13th year, the RAC Cooling Industry Awards champions the leading innovations and environmental successes in the refrigeration and air conditioning industry. JD Cooling were voted as winners by the judges for our pursuit of two fundamental goals - our quest to improve what we offer our customers and our own workforce, whilst growing significantly in the industrial sector with our forward-thinking attitude when it comes to natural refrigerants.
The judges enthused that JD Cooling’s “commitment to staff development is exemplary” and that we have “a genuine passion for business improvement and continuity”. Receiving the awards along with other members of the JD team, John Dye, JD Cooling managing director said, “We are delighted to be recognised highly within the industry for our achievements over the years. This is a huge accomplishment for our business and one that we dedicate to all our employees, as without them, we wouldn’t be where we are today.” For more information about the awards and to see the other winners from the night, please follow this link https://coolingawards.racplus.com 07 | AMP Magazine Issue 40
MULTILINE E sets new connection standards The MULTILINE series from Eisele is based on a modular kit principle that is easy to handle. As a recent addition, MULTILINE E offers adaptive inserts for electrical and electronic connections that also provide options for electric power supply. The robust system is additionally available in a version that is compatible with standard industrial connectors. All of the modular components can be easily assembled without tools.
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he pioneering concept of the MULTILINE ADAPTIVE from Eisele is used for connecting functional groups to machines. A modular kit system with adaptive inserts allows combination of exactly the connections required for a particular application, in one multiple connector. Installation expense and set-up times can be reduced significantly. Thanks to the fully modular principle it is possible to combine such different connections as pneumatics, gases, coolants, fluids and even adaptive inserts for electrical and electronic connectors in a single interface.
The MULTILINE E modular kit system allows individual configuration of connections for liquids, compressed air, gases, electric power or electronics in one multiple connector
In cooperation with Murrelektronik GmbH, Eisele has continued development of the MULTILINE ADAPTIVE to create the MULTILINE E. The unique adaptive inserts can also be equipped with electrical and electronic connections from the Oppenweiler-based company. Depending on the application, M12 round connectors or other connector types for bus systems, control technology and power supply can be used. Furthermore, tube connections can be integrated. In addition to combined concepts for different control lines, complete solutions are also possible for electrical and electronic connections.
holes for the standardized outer geometry of the adaptive inserts now feature an additional slot to prevent twisting of the electro inserts and guarantee the correct polarity of the E-connectors. The asymmetrical bore pattern eliminates the danger of incorrect assembly of the connector. The full range of products available from Murrelektronik provides practically unlimited possibilities for configuration of the MULTILINE E.
Eisele optimized the design of the base body for the integration of the E-connectors, which is available in stainless steel or anodized aluminum. The bore
The E-connector line is being launched with the widely used and standardized M12 round connectors in different constructions for diverse applications. They include
AMP Magazine | 08 Issue 40
Individual connections in series
A-coding, three to twelve pins, Cube6, Profibus and Ethernet. The Eisele engineers have also added a version of the M12 power plug for power electronics up to 630 volts: the M12 power plug in accordance with IEC 61076-2-111 is the smallest and most compact connector on the market and is designed for cables with diameters up to 2.5 mm2. The adaptive insert with five power contacts supplies up to 16 A per pin. The new power connector is protected against reverse polarity, vibrations and shock. The MULTILINE E will be successively expanded to include additional versions based on customer requirements. The entire product spectrum of Murrelektronik is accessible for this purpose.
Flexibility also with respect to the connecting cables The possible options for configuration of the connection cables are completely open. They are available in drag-chain compatibility, halogen-free or chemical-resistant versions or with all standard electric certifications in any length needed. The connection cables can either be connected to the corresponding adaptive inserts with pre-configured plugs or they are available as ready-made cable assemblies. Of course, users also have the option of ordering cables with free ends for their own custom cabling of the connections. The MULTILINE E provides the first truly multimedia interface, which also allows fast and easy adaptation.
The optimal industrial connector from Eisele With the development of the MULTILINE ADAPTIVE and the MULTILINE E, Eisele Pneumatics GmbH & Co. KG has implemented ambitious goals in the form of a completely new type of product. The Waiblingen-based experts for solid metal connectors are also focusing their attention on the current standard solution for the central supply of machines and systems: conventional industrial connectors are widespread. Numerous systems use this type of connector for their electrical interfaces, so they represent a historically evolved market standard, which owes its popularity in particular to the robust housing design.
The E-connector line is being launched with the widely used M12 round connectors in different constructions for diverse applications
The Eisele MULTILINE INDUSTRIAL CONNECTOR is compatible with Eisele adaptive inserts and all standard industrial connectors
However, these connector systems also have significant disadvantages: their assembly requires the use of tools and the plastic inserts, as opposed to the housings, are fragile and not particularly durable. In the event of errors such as loose contacts, troubleshooting is time-consuming. Defective components often have to be replaced instead of repaired.
Modular design – no tools Eisele’s response to these disadvantages is the application of the modular kit concept of the MULTILINE ADAPTIVE and MULTILINE E to the standard industrial connectors, through the use of robust adapters. Eight connections can be integrated in one such adapter. Thanks to the perfect compatibility of the modular design, different connection types and media, as well as different connection diameters, can be flexibly integrated in the industrial connectors. The entire supply of the machine – not only the electrical and electronic connections – can therefore be implemented in a single interface.
With an M12 power plug and a practical locking lever Eisele’s MULTILINE modular kit system now offers even more diversity and service
The development potential for multiple connectors is therefore by no means exhausted. For superfast connection and release with little manual strength, the MULTILINE E is now optionally available in a version with a practical locking lever. www.eisele.eu www.eisele.eu/produkte/multiline/ www.murrelektronik.com/de/home.html 09 | AMP Magazine Issue 40
A unit that was originally designed to help ensure the batch consistency of bakery products has found a new home within a wide range of manufacturing industries.
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very baker knows that to produce batch consistency you need an identical amount of ingredient each and every time. You also need an identical volume of water – and that’s not easy to achieve. Bakers simply cannot afford to indulge in guesswork when working with volumes of water; delivery to the mixing bowl by way of buckets of water or hosepipe is messy and open to operator error. However, many bakeries use a water measuring system called the ABACUS - which achieves accuracy and repeatability. Hoddesdon-based John Morton, of Aquameter Ltd, who designs and manufacturers the units explains that it is a digital micro-controlled device that delivers exact, pre-selected quantities of water from a single pipe straight into the mixing vessel. John says: “The precise metering of the water means that the operator can exactly recreate batch consistency every time. The ABACUS is now finding a home in many other manufacturing processes and is perfectly suited to any process in which water is added to any other ingredients – such as powders, granules or pastes that are used in the manufacturing process.
Micro Metalsmiths, Kirkby Moorside, have taken the unit on board. The company produce non-ferrous metal castings; precision components for the aerospace and microwave industries. At the heart of the operation is a “lost wax” process. This involves producing a wax image of the casting, which is then encased in a mould. This mould is a plaster-silica blend, which uses exact quantities of water with which to blend the components. This mix is then poured around the wax and allowed to harden. That done, the wax is burned out at high temperature, the molten metal poured in, and the mould broken away to reveal the finished casting. Originally, they used a balance beam system for measuring out the water. It had a central pivot which was weighted at one end. The water flowed in and balanced out… archaic and not particularly accurate.
Derek Baxter, International Projects Director with Filtrona International in Jarrow, says of the system: “We use the unit for metering water into a carbonpowder mix.
Other alternatives would have involved the company investing heavily in load cell weighing or some form of volumetric measuring device. He says: “The ABACUS is relatively inexpensive and reliable. It takes minutes to install and is of negligible cost to run.”
Were it not for these units we would be using buckets of water, a line of hose, or a constantly changing mark on the tank - not that convenient.” He goes on: “With this thing we just dial new numbers in, and away we go... it’s obviously more accurate; using the meter than relying on staff to put it in by pail.”
Little wonder that the unit is catching on in manufacturing processes outside the industry for which it was originally conceived.
AMP Magazine | 10 Issue 40
For further information: John Morton, Telephone 01 992 442 861
11 – 15 June Frankfurt / Main
BE INFORMED. BE INSPIRED. BE THERE. › World Forum and Leading Show for the Process Industries › 3,800 Exhibitors from 50 Countries › 170,000 Attendees from 100 Countries
www.achema.de
ACHEMA 2018: Great Expectations for the World Forum of the Process Industries
Some 7 months before the start there are unmistakable signs that ACHEMA 2018 will be a crowd-puller. Almost 2900 exhibitors from all around the globe have already booked a stand at this leading show for the process industries in Frankfurt am Main. From 11 to 15 June 2018 they will be showcasing their innovations for the chemical, pharmaceutical and food industries from laboratory to large-scale plant through to the packaging line. And there is no lack of topics: the energy turnaround, novel antibiotics, water treatment and innovative materials, to name but a few – chemistry and process engineering present solutions for practically all sectors. Given the immense interest of exhibitors, the organizers anticipate a corresponding rush of visitors. More than167,000 participants are needed to exceed the figure for the last event in 2015 which for one week made Frankfurt am Main the epicentre of the global process industries. Those who have not yet booked their space will have to hurry! An extra hall has already been rented to absorb the present excess demand, nevertheless there is every indication that ACHEMA 2018 will be fully AMP Magazine | 12 Issue 40
booked. This particularly applies to pharmaceutical technology and automation where the demand for space has already exceeded supply. Moreover, the “classical” ACHEMA exhibition groups, such as pumps, process engineering and the laboratory sector, have also shown a keen interest. Hence, ACHEMA 2018 is once again set to live up to its reputation of being not only the market place of the present, but also the innovation exchange of the future. “Many challenges, be they energy efficiency, shorter product cycles or novel materials for applications spanning vehicles to power stations, impact this sector worldwide”, explains Dr. Thomas Scheuring, CEO of DECHEMA Ausstellungs-GmbH. “That makes the event far more than just a trade venue – ACHEMA is where global trends are launched.” Besides business transactions at the fair, discussions at the stands and in the lecture halls are the heart and soul of ACHEMA. If no market-ready solution exists, what better place to go for an exchange of ideas and experience than the Congress featuring some 800 lectures! As Prof. Kurt Wagemann, CEO of DECHEMA e.V. which organizes the Congress programme, comments: “The speakers are literally face-to-face with the technology in question. This creates an atmosphere for truly application-oriented discussions.” Whether it be the energy turnaround, digitization, availability of resources or novel concepts for biotechnological processes – the Congress programme already promises to provide a wealth of interesting insights for participants both from science and industry. Three trends demand the special attention of stakeholders in the global process industries: “Biotech for Chemistry” underscores the increasing integration of chemical and biotechnological processes. It is no longer a question of “either-or”, but of the optimum combination of these two worlds, from strain development through to product – with all the challenges
this entails for processes and processing methods. At the same time the demands made on “Flexible Production” are soaring – whether it be different regional requirements, varying energy and raw materials supplies, shorter product cycles or customised production: flexibility is the key to success on the dynamic global markets. The solutions include modular plants, robust processes and intelligent components which, thanks to digitalisation, communicate with each other and integrate many tasks into the plant from process adjustment to predictive maintenance. These developments are inconceivable without the integration of “Chemical and Pharmaceutical Logistics” which is progressively
making a transition from service provider to systems partner. Data exchange across the whole supply chain, track and trace systems even for the smallest loads, while still remaining committed to safe and punctual transport of raw materials and products – all these factors make for the success of a globalised sector. In the exhibition, congress, and the application-oriented PRAXISforums which bring together suppliers and customers in close proximity to the individual exhibition groups, and also in a variety of accompanying events and publications, these topics will be just as intensively explored and discussed as all the other topical developments that impact the process industry today and tomorrow. 13 | AMP Magazine Issue 40
NORD DRIVESYSTEMS at CBST 2017 in China
The 8th China International Beverage Industry Exhibition on Science and Technology (CBST) will take place in Shanghai from 22 to 24 November 2017. NORD DRIVESYSTEMS, one of the world’s leading drive specialists, will be there again this year. The internationally operating company with head office in the north German city of Bargteheide and sites in China (HQ and motor production plant in Suzhou, assembly plant in Tianjin) will be at the renowned trade fair in the Shanghai New International Expo Centre (SNIEC) to present innovative technologies and products, current Industry 4.0 applications as well as energy and cost optimisation concepts for the beverage industry. NORD DRIVESYSTEMS will introduce nsd tupH, among other things. This a surface conversion system that protects against corrosion and chemicals as well as high-pressure and steam jet cleaning. nsd tupH makes aluminium geared motors as resistant as stainless steel products, is significantly more effective than anti-corrosion paints and offers excellent value for money. Drive systems count among the main consumers of energy in industry. Energy efficiency is therefore a major issue. The new energy-efficient smooth motors of NORD DRIVESYSTEMS have higher efficiency than previous models and thus contribute to the reduction of operating costs. Their smooth surfaces make them especially suited for applications in the food and beverage industry. The successful NORDBLOC.1 series was also expanded. With the new two-stage bevel gear units for output torques of up to 50 Nm, high-efficiency helical bevel gear units (in addition to worm gear units) are now available as well for the small load range. These gear units have a very high mechanical load-bearing capacity and are resistant to high forces on the output shaft. The new models are available for gear ratios ranging from 3.03 up to 47.67:1. They are added to the current series that now consists of six sizes with torques of up to 660 Nm. Different gear unit and motor types, sizes, options and gear ratios often result in a large variety of drive versions. A reduction in variety can result in optimised processes and costs. The high-efficiency two-stage bevel gear units with IE4 synchronous motor, power plug and ready-made cable offer a solution for intralogistics in the beverage industry. Advantages: considerable reduction of spare part stocks; service friendly using plug-and-play technology; compact, space-saving design as well as 25 percent weight savings because of a lightweight aluminium housing.
nsd tupH is a special surface conversion system to protect against corrosion and chemicals, making aluminium geared motors as resistant as stainless steel products
capacity. Maintenance costs are reduced and the drive’s service life extended. From unpacking, conveying and cleaning, filling, sealing and labelling to packaging and palletising, NORD DRIVESYSTEMS offers a variety of reliable, efficient and safe solutions for the beverage industry. You will find NORD DRIVESYSTEMS at the CBST in building N1, booth 1A02. www.nord.com
NORD has now expanded the product range of industrial gear units to eleven sizes. This makes NORD DRIVESYSTEMS the only manufacturer that produces modular industrial gear units with an output torque of up to 250,000 Nm in a one-piece unicase housing. The design principle was developed at NORD in 1981 and it ensures maximum radial and axial load-bearing capacity. Extend service intervals and reduced downtimes – these become possible with predictive maintenance. The collection, analysis and transmission of drive and application data permit the as-required planning of maintenance assignments based on the production AMP Magazine | 14 Issue 40
LogiDrive is an energy-efficient, maintenance-friendly and standardised drive solution especially for applications in intralogistics and the food industry
ConveyorTek Receives Recognition for Newly Launched Metal Detector Northern Ireland based ConveyorTek Ltd has received the prestigious 2017 Materials Handling Engineers Association (MHEA) ‘Innovation Excellence Award’ for its newly launched conveyor metal detector.
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he Company, which designs and manufactures bespoke conveyor solutions and metal separation technologies, was among five winners at the awards function in Eastwood Hall hotel in Nottingham. The awards ceremony took place as part of the annual BulkEx technical conference and exhibition on 18 and 19 October. ConveyorTek won the Innovation Award for its highperformance conveyor metal detector that can selfcalibrate and, uniquely, can ignore steel cable belts and rip detection systems, while still detecting rogue metal pieces. According to ConveyorTek, it has been many years since a new conveyor metal detector has appeared on the UK market that has been truly innovative in its electrical technology, programming and housing materials. Working with an expanding team of in-house and external specialists, this product has been developed over the last two years and has recently launched into the market. The product is completely manufactured at the Company’s facilities in Northern Ireland. The metal detector uses a ‘pulse induction technology’ which is generated by creating a pulsing magnetic field with a series of sealed sense coils and excitation coils. The housing has been designed with a very innovative assembly procedure allowing customers to install the detector in under 40 minutes. It comprises of adjustable sensitivity; engineering and performance diagnostics; a series of extra alarm options and notifications; and is arguably the most robust metal detector in the UK bulk handling market. From the initial design concept to a series of working prototypes, the metal detector is now delivering excellent performance results and the company is currently beginning to establish a global distribution network for its sales representation. Indeed, the Company has just secured its first large order with one of the industry’s leading quarrying applications for a 2000mm wide system that will be installed in November of this year.
ConveyorTek’s Phil Trimble receives MHEA Excellence in Innovation award at BulkEx17
Philip Trimble, Managing Director of ConveyorTek had this to say: “We believe that the competitive price, fast assembly procedure, extremely robust frame and high detection capabilities will, in time, make this metal detector the new industry benchmark”. The MHEA, which works to support the interests of companies supplying and using bulk handling equipment around the world, explained that “the awards were conceived to recognise and reward the talent and creativity of the association’s members and the world-class capabilities of its member companies”. Michael Kaye, outgoing President of the MHEA, said: “Once again, the MHEA Excellence Awards dinner was a huge success and provided us with a platform to highlight some of the fantastic achievements in bulk materials handling. The judges were very impressed with the standard of the entries – our congratulations go to all the winners”. Receiving the award at the sold-out evening function of BulkEx17, Philip Trimble, MD at ConveyorTek said, “We are delighted to receive such a prestigious industry award from the MHEA. Investment in R&D is at the forefront of our Company and I am pleased to accept the award on behalf of our team. We are continuing to work on new, innovative products for the conveying industry and have more exciting projects in the pipeline”. Last year’s winner of the Innovation Award was industry giant Siemens, which goes some way in demonstrating the calibre of nominees in the category. The ConveyorTek award comes close on the heels of the Company’s rebrand which now includes the tagline “technical excellence”, the main attribute that ConveyorTek believes sets it apart from its competitors. www.conveyortek.com
15 | AMP Magazine Issue 40
SG Transmission celebrates 45 years!
British manufacturer SG Transmission is celebrating its 45th anniversary, a milestone that shows its commitment to innovation in an ever changing motion control industry. Established in 1972, SG Transmission has developed a strong global client base due to its focus on research and development and its ability to design and manufacture its products under one roof. While the company has a standard portfolio of electromagnetic brakes and clutches, SG Transmission provides original equipment manufacturers (OEMs), distributors and end users all over the world with a customised design service. In 2015, the company’s engineers created a clutch with an electromagnetic toothed lock in response to an enquiry from a brand leader in the medical devices market who was experiencing problems. SG Transmission produced a hybrid product combining the unique characteristics of three products, a solenoid, a toothed brake and a torque overload friction coupling. SG Transmission launched its ultra-slim, permanent magnet brake in 2016, designed initially for a robotics manufacturer to save on space and weight. The fail-safe brake has a small outside diameter and a brake field of less than 13mm, with a comparatively large bore through the centre AMP Magazine | 16 Issue 40
for the application’s drive shaft. SG Transmission’s ultra-slim permanent magnet brake Unlike other clutch and brake manufacturers, SG Transmission prides itself on its six week lead time for prototype designs. Andy Collinson, CEO, said: “The motion control industry is changing and we have become more flexible in our processes to cater for this. Along with the six week prototype lead time, we can offer a four week production lead time due to all of our manufacturing capabilities being under one roof within our factory in the North East of England. “The products are designed and manufactured by the same project teams who see things from inception to completion, which means all of our engineers have an understanding of the customer’s requirements.” SG Transmission is part of the British Engines Group, comprising of seven engineering businesses operating across the world. Formed in 1922, the British Engines Group which reported a turnover of £154.4m in 2017, gives its businesses the stability and ongoing support to compete with global competitors.
Production Scheduler, Keith Thompson and CEO, Andy Collinson
SG Transmission’s ultra-slim permanent magnet brake
Keith Thompson, Production Scheduler at SG Transmission has been working for the company since 1983: “The business has changed massively since I started 34 years ago, we were originally a team of 10 with only two central lathes and one CNC lathe! “We are receiving new enquiries from global equipment manufacturers every day and my job has never been more exciting. The order quantities may have increased, but we have still managed to retain the capacity to service the niche, smaller quantity, bespoke market.” SG Transmission designs and manufactures its products from its purpose built factory in County Durham. Although the business has benefitted from a considerable amount of growth over the past five years, it still stands by its successful small company ethos. www.sgtransmission.com
More efficiency, less costs
With ASACLEAN™ GL2 by VELOX Maxell Moulding Services has found the ideal purge compound With over 22 years of experience in manufacturing and packaging precision moulded plastic components, Maxell Moulding Services (UK) is very experienced in many aspects of polymer processing. Yet they were surprised when, in search for a new and efficient purge compound, Maxell’s technicians tested ASACLEAN™ GL2 provided by VELOX GmbH. “The performance of ASACLEAN™ GL2 was outstanding in every aspect”, says Hugh Davies, Moulding Technician at Maxell. “It does not only clean the machine within only 15 minutes and thereby minimises the downtime, but we could also save money by using 50 percent less purging material compared to other purge compounds. Additionally we received great expert consultation and support by VELOX.” The Request: Purging material for lowering scrap and minimising downtime Maxell Moulding Services was looking for a highly effective purge compound in order to have their production run as lean as possible in between colour or material changes. As Maxell offers plastic moulding services for most exacting applications in the medical, food and especially the automotive and electrical industry, the company also has high demands when it comes to purging. Following the trials of several purging agents from different suppliers, Maxell came to the conclusion that ASACLEAN™ GL2 serves their purpose best. After having emptied the screw and barrel from a run of 30 % glass filled black ABS, Maxell used only 8 kg of Asaclean™ GL2 before going on to a white polystyrene (PS) on a 80 mm diameter screw. No black streaks or spots were left to be seen in the PS producing an excellent result. “With our previous purging compound we were purging for 3 to 4 hours until, finally, clean material came out of the machine”, says Hugh Davies. “This was too long, too expensive and too inefficient for us. Then we tried the Asaclean™ GL2. All it took us was 8 kg instead of 16 kg and, after only 15 minutes of purging, the machine was clean. No screw needed to be pulled and we were ready to start the next production run right after.” The Solution: A powerful and easy to use purging all-rounder ASACLEAN™ GL2 is a purge compound best suited to clean screws and barrels and for applications as injection moulding and extrusion. Produced by Asahi Kasei
Chemical Corporation, Japan, ASACLEAN™ GL2 belongs to the purge compound family Asaclean™ with 15 additional types for various special applications, such as in the high-temperature range, transparent applications and others. It combines properties of efficiency as well as high purging power. Moreover, it is neither abrasive nor corrosive and is an all-rounder grade appropriate for hard cleaning, especially during colour changes, material changes to standard polymers, sealing and hot runner cleaning. ASACLEAN™ GL2 works within a temperature range of 180°C to 330°C – if necessary, up to 360 ° C, if an exhausting system is available. VELOX GmbH (www.velox.com) has been the exclusive pan-European distributor for Asaclean™ since 1995. The company offers 16 different grades which target specific challenges in all aspects of purging from injection and blow moulding to masterbatch and compound extrusion. “Asaclean™ is a ‘ready to use’ granulate solution that does not require mixing or predrying and no temperature adjustment on the machine”, says Enno Stapel, Product Manager at VELOX and responsible for Asaclean™. Likewise, each single granulate is cleaning-active, “there is power in every pellet”, explains Stapel. In the global purging compound market, VELOX GmbH and its partner Asahi Kasei Corporation are among the top four companies, according to a recent study by market research company Transparency Market Research. Benefits for plastics processors: Application specific product combined with qualified service With the comprehensive Asaclean™ purge compound range, VELOX offers every plastics processor a targeted solution and this can be distinguished from many “compromise cleaners” which have to solve a wide range of purging challenges with a few product types. “This customised approach has proven very helpful for our customers and greatly successful for VELOX”, says Enno Stapel. Moreover, as a solution provider, VELOX not only delivers the specific products, but also offers professional advice, assistance with selecting the right type, free samples, instructions for correct cleaning in font and film form, support for type selection, technical assistance as well as trainings on site. “We are delighted to see that after a free consultation, combined with a trial by
Fast and effective: color change to transparent materials with ASACLEAN™
Sealing with ASACLEAN ™: preventive oxidation protection during maintenance and weekend shutdowns for faster re-start without scrap
Sealing with ASACLEAN ™: preventive oxidation protection during maintenance and weekend shutdowns for faster re-start without scrap
Maxell Molding Services achieved high time, material and cost savings with ASACLEAN ™ GL2
our local sales agent VELOX U.K. Ltd, ASACLEAN™ GL2 worked out as well as it did for Maxell Moulding Services. This is another success of the ASACLEAN ™ family as a problem solver for our customers.We look forward to a long lasting business relationship”, comments Stapel. 17 | AMP Magazine Issue 40
Climbing the ranks in automation As the world’s largest exporter of manufactured goods, many companies rely on China to provide them with cost-efficient products. However, should we be looking to smaller countries to provide high quality products at low prices? Here, Jonathan Wilkins, marketing director at obsolete industrial parts supplier, EU Automation, explores the role of countries emerging as leaders in manufacturing. The top three countries that are leaders in manufacturing have remained fairly similar over the last few decades. The US, China and Germany have continued evolving to export a large amount of products to the world. To remain high in the ranks, these countries have adopted automation, optimised their manufacturing processes and advanced production processes. Strong economy and large populations suggest that these countries will remain leaders in manufacturing and automation for years to come. However, as the industry grows, smaller countries are beginning to emerge as competitors in the industry.
North and South America
economy, Mexico excels in a range of industries such as aerospace, automotive and food and beverage. The automation industry in Mexico is growing rapidly, with over 6,320 robotic units sold in 2015, tripling previous figures. Mexico is also looking to greaten its presence in the global manufacturing industry by increasing company growth. The country is the first Spanishspeaking nation to partner with Germany at Hannover Messe 2018. At the trade show, Mexico intends to exhibit its new technologies and strengthen its international trade relations.
Central Europe
Many countries in South America are driven by manufacturing. For example, in Chile, manufacturing contributes towards around 16 per cent of the gross domestic product (GDP) and over 14 per cent of the working population are employed in a manufacturing role.
Western European countries such as the UK and Germany are regarded as the manufacturing leaders of Europe. However, some central European countries have rapidly growing economies due to their investment in manufacturing. Poland, for example, has seen its economy triple in the last decade.
States in Northern America are also looking south to improve their manufacturing sector. As the world’s eleventh largest
Manufacturing exports contribute towards 33 per cent of the GDP in Poland, compared to an average of 22 per cent among other
AMP Magazine | 18 Issue 40
emerging nations. With a population of over 40 million, more jobs are created to meet the industry demand and support the growing economy. Poland’s increasing presence in the manufacturing industry was highlighted when they were invited to be the partner country exhibiting at Hannover Messe 2017. As one of the fastest growing markets for automation, the country is now one of Germany’s most lucrative trading partners.
The Mighty-Five The Asia Pacific region is one of the key players in automation, with Japan and China relying on automated factories to ensure a successful manufacturing industry. Smaller countries are beginning to invest in this technology to experience the benefits and grow their economies. A group of countries known as the Mighty-Five are expected to rapidly evolve as manufacturing competitors over the next decade. Malaysia, India, Thailand, Indonesia and Vietnam aim to invest in automation to offer the world low cost labour with high quality results. The countries each excel in different areas of automation. India’s economy, for example, relies on the IT industry as the largest private employer in the country. Between 2013 and 2014, India exported over $167 billion worth of IT and software services. The industry is expected to improve further as standard of living continues to improve in the country. These countries still have a long way to go to compete with manufacturing giants, such as China or the US. Yet the rapid growth of automation in these countries suggests that the global manufacturing sector may look very different in a few decades.
WALTER ADDS TO ITS DIGITAL ENGINEERING KOMPETENZ BY ACQUIRING COMARA
With the acquisition of its long-standing software partner Comara GmbH, tooling expert Walter is reinforcing its decision to strive for further growth in the digital sector and build on the company’s Engineering Kompetenz. As Walter AG President, Mirko Merlo, states: “This is a key strategic step towards expanding our digital portfolio and further developing our company towards Industry 4.0.”
Acquiring Comara constitutes the next logical step in Walter’s development from product to process partner, he says, and now to digital process partner, too. The objective is to be able to understand and interpret processes in a holistic way and to develop digital solutions that enable Walter’s customers to boost their productivity and efficiency across the entire process chain – again demonstrating how, together with customers, Walter will always find the best solutions. Comara will remain an autonomous operation with separate products and its own retail arm.
19 | AMP Magazine Issue 40
JJ Churchill reorganises to give an ‘absolute focus’ to aerospace and gas turbine industries Restructure evolves top team and will meet the growth challenges ahead
JJ
Churchill today announced that it is reorganising to give an absolute focus to the aerospace and gas turbine industries. The company now needs a structure that reflects the different demands of these important industries in order to meet the growth challenges ahead. The gas-turbine side of the business is becoming more focused on volume blade manufacture and the aerospace side is gearing up for high growth. Where appropriate, the functions and responsibilities of all employees and departments are being clearly identified “Aero” or “Diesel” teams. Over the coming weeks, as this new structure is deployed, business will continue as usual, meeting strong production targets. The reorganisation also involves moves at the top of the company, with Managing Director Andrew Churchill becoming Executive Chairman; and Engineering and Sales Director Mark Cooper being promoted to Managing Director. The current Chairman, James Churchill, becomes President and retains a watching brief. The company is focused on ‘sticky niches’ - niches which require a high degree of technical and organisational skill. It works in areas which require highly skilled engineering in difficult geometries, difficult dimensions and challenging materials – the type of project where the first reaction is: “That can’t be done”. Andrew Churchill said, “These changes signal a very exciting, next phase of our development. They will enable JJ Churchill to meet the growth challenges ahead and to give an absolute focus to
AMP Magazine | 20 Issue 40
gas turbines and aerospace. They will enable us to build on our existing strengths while developing new capabilities and greater capacity.” Mark Cooper added: “I am really pleased to play a part in this, the latest stage of the company’s evolution. Everyone within the business has a relentless focus to deliver, day-in day-out, for our customers. This reorganisation will develop and deepen expertise across the whole staff team.” For more information about JJ Churchill, visit www.jjchurchill.com.
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350 million tonnes of reserves:
VELOX announces sale of highquality calcium carbonate in Europe VELOX GmbH, a leading panEuropean distributor of raw material specialities and solution provider for the plastics, composites, rubber and paints & coatings industries, is now offering customers across Europe an exceptionally highquality calcium carbonate (CaCO 3 ) for use in adhesives and sealants, interior and exterior paints as well as plastic compounds. The material features extremely high purity and whiteness combined with high quality and homogeneity.
The natural calcium carbonate is extracted and refined at inhouse plants by VELOX’s Croatian partner White Rock Minerals, one of the country’s leading exporters of mineral raw materials, holding approximately 350 million tonnes of reserves of this extremely white limestone. “The calcite fillers offered by VELOX Purity > 98.5% feature chemical purity of over Heavy metals <0.0005% 98 percent and, at a Ry value of Iron oxide <0.01% >95.5, achieve a very high degree of Whiteness (Ry) >95.5 whiteness”, says Marten Reimers, Yellowness <2.0 Product Manager CASE (Coatings, Adhesives, Sealants and Elastomers) at VELOX. This results in numerous advantages for the different user groups. Calcium carbonate is the major extender in paints and coatings. Its fineness and grain size distribution can help improve the opacity of coating systems. “With minimum heavy metal and iron oxide content, CaCO 3 is much in demand by manufacturers of high-grade emulsion paints as well as compounders who rely on top quality and wish to avoid troublesome impurities”, explains Reimers. “As iron oxide residues can cause efflorescence in plasterwork and façade paints, calcium carbonate’s purity ensures highly durable coatings.” In plastics processing, calcium carbonate is by far the most important mineral. Thanks to a high level of whiteness, the CaCO 3 fillers from VELOX help save on white pigments such as titanium dioxide that are not only expensive but also abrasive. “Limestone fillers are also softer and less crystalline than comparable marble powders, helping preserve machinery”, adds Reimers.
LEFT: VELOX sources its high-quality calcite fillers from rich reserves in Croatia. RIGHT: White Rock Minerals refines the carefully extracted calcium carbonate at their own production sites.
www.velox.com AMP Magazine | 22 Issue 40
Other applications of calcium carbonate include rubber processing, carpet backings made of foamed latex, sealants and adhesives, glass production and composites. As distributor of high-quality calcium carbonate, VELOX provides decentralised and flexible logistics across Europe, ensuring rapid deliveries. The product is shipped from strategically positioned handling centres, avoiding transport routes longer than 300 km. Bespoke solutions and consulting continue to be available for the various applications. “We are delighted to be adding high-quality CaCO 3 from our partner White Rock Minerals to our specialist portfolio. With 350 million tonnes of reserves, we are strategically well-positioned and ready for the future in view of the significant demand for this product from numerous sectors”, concludes Reimers.
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23 | AMP Magazine Issue 40
Moog Extends its Electrohydrostatic Pump Unit Offering with More Sizes and Available Options The product family now includes the size 80 cc to help machine builders address a wider range of applications
M
oog (NYSE: MOG.A and MOG.B) – a designer and manufacturer of high performance motion control products, solutions, and services, enlarged its product range of Electrohydrostatic Pump Units (EPU) with the EPU size 80cc in order to help customers address a wider range of applications. The product line now includes the sizes 19, 32 and 80 cc. The EPU size 80cc is ideal for machine builders and operators seeking cleaner and more energy efficient options that meet the requirements for high force actuation. The Moog EPU enables the deployment of a decentralized drive system and eliminates the need for a hydraulic power unit (HPU) and complex piping thereby reducing the overall machine footprint. The compact product design features a unique interface that enables direct mounting on to a cylinder thereby minimizing the requirement of additional space on each axis and enabling easier installation and maintenance for a lower total cost of ownership.
Highly versatile, the Moog EPU has been developed to meet the needs of original equipment manufacturers (OEMs), system integrators and end-users for a large variety of industries such as metal forming and heavy industry, plastic machinery, gas and steam turbines and wind turbine pitch control. “With this product portfolio expansion, Moog offers new options to machine builders in order to help them address a wider range of applications”, says Robert Luong, Marketing Manager at Moog Inc. “Our customers are requesting a range of product sizes and flexible options that will allow machine designers to use our EPU on different machine models and sizes”.
The EPU is the heart of Moog Electrohydrostatic Actuation Systems (EAS) which is a compact alternative to traditional electrohydraulic or electromechanical actuation systems for applications with high force requirements. The Moog EAS is a modular actuation system comprised of the EPU, a Servo Drive (MSD), manifold and an optional cylinder.
www.moog.com
AMP Magazine | 24 Issue 40
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